Force-Sensed Expanded Hole Inspection for Misalignment Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for identifying mis-aligned holes, such as out-of-tolerance drilled holes, in structural components are time-consuming, labor-intensive, and lack accuracy, especially when using automated probe inspection systems.
Innovation Solution
A system comprising a control unit that receives force signals from force sensors attached to a tool or end effector, compares these forces with reference data from a aligned hole, and determines if the hole has been deformed based on differences in force data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection methods are used to identify hole deformations, then labor intensity and time consumption increase, but measurement accuracy can be maintained through careful human observation
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical measurement system that uses image capture and analysis to detect hole deformations. The system captures images of holes during drilling operations and automatically analyzes them to identify deformations such as snow-manned, eyebrowed, or double-drilled holes, eliminating the need for manual inspection while maintaining high measurement accuracy.
2Productivity
If automated probe inspection systems are used to identify hole deformations, then productivity increases and inspection time decreases, but measurement precision deteriorates as these systems cannot accurately identify hole deformations
Solution Approach 1:
The patent replaces traditional automated probe inspection systems with an optical measurement system that captures images of holes during drilling operations. This optical approach enables accurate identification of various hole deformations including snow-manned, eyebrowed, and double-drilled holes, achieving both high productivity and measurement precision that probe systems cannot deliver.
Solution Approach 2:
The system creates optical copies (images) of the holes during the drilling process and analyzes these copies to detect deformations. By working with image data rather than physical probe measurements, the system achieves superior detection accuracy for subtle hole deformations while maintaining automated high-speed inspection capabilities.
3Measurement precision
If automated optical measurement systems are implemented, then both productivity and measurement precision improve, but device complexity increases due to the need for image capture and analysis capabilities
Solution Approach 1:
The patent merges the inspection function with the existing drilling operation by capturing images during the drilling process itself. This integration allows the system to perform both hole formation and inspection in a single operation, reducing overall device complexity compared to separate inspection systems while achieving superior measurement precision through optical analysis.
Data Source
Figure 1~3
Figure 4A
Figure 4A
AI summary
A system includes a control unit configured to receive one or more force signals from one or more force sensors coupled to one or both of a tool or an end effector. The one or more force signals are indicative of one or more forces exerted in relation to the tool or the end effector as the tool operates on one or more components to form an expanded hole. The control unit is further configured to compare the one or more forces in relation to force data associated with a reference expanded hole that is aligned with an alignment hole of the one or more components. The control unit is further configured to determine that the expanded hole caused a deformation when the one or more forces differ from the force data.